Sel Genesis 240 TLH Instrucciones de funcionamiento

REPAIRS MANUAL

Genesis

240

Genesis

240 TLH

Cod. 92.08.011

Edition: 11/99

SELCO s.r.l.

Via Palladio, 19

35010 ONARA DI TOMBOLO (Padova) Italy

Tel. 0499413111

Fax 0499413311

INDEX :

1) GUARANTEE CONDITIONS

. . . . . . . . . . . . . . . . . . .84

2) PURPOSE OF THE MANUAL

. . . . . . . . . . . . . . . . . .85

3) MACHINE TECHNICAL SPECIFICATIONS

. . . . . . . .85

4) DESCRIPTION OF MACHINE PARTS

. . . . . . . . . . . .86

5) DESCRIPTION OF MACHINE OPERATION

. . . . . . .88

LAY-OUTS OF CARDS

. . . . . . . . . . . . . . . . . . . . . . .104

6) DESCRIPTION OF DIAGNOSTIC INDICATIONS :

. .116

- EXTERNAL

- INTERNAL

7) AVAILABLE SPARE PARTS

. . . . . . . . . . . . . . . . . . . .119

8) WARNINGS, PRECAUTIONS, GENERAL

INFORMATION ON EXECUTING REPAIRS

. . . . . . .121

9) DIAGNOSTIC AND REPAIR INSTRUMENTS

AND TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

10) DIAGNOSIS PROCEDURE :

. . . . . . . . . . . . . . . . . . .122

- LEVEL 1

- LEVEL 2

11) PARTS DISMANTLING AND RE-INSTALLATION

PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

12) OPERATING TESTS AND SETTINGS

. . . . . . . . . . . .159

13) TELEPHONE ASSISTANCE

REQUEST PROCEDURE

. . . . . . . . . . . . . . . . . . . . .164

1) GUARANTEE CONDITIONS.

To specify the present warranty conditions , we remind that

SELCO does not repair under warranty the damages

a) resulting from attempts by personnel not allowed by SELCO

to install, repair or service the products

b) resulting from improper use or connection to incompatible

equipment

c) in products that have been modified or integrated with other

products when such modification or integration can be the

cause of the failure.

84 Guarantee conditions

Power supply voltage

(50/60Hz)

Max. absorbed power (x=40%)

Max. absorbed current (x=40%)

Absorbed current (x=100%)

Efficiency (x=40%)

Power factor (x=40%)

Cosj(x=40%)

Welding current (x=40%)

(x=60%)

(x=100%)

Adjustment range

Open-cicuit voltage (limited)

Protection rating

Insulation class

Construction standards

Dimensions (lxpxh)

Weight

3x400V

+10% -10%

8.4 KW

12.9 A

7.9 A

0.84

0.94

0.99

240 A

185 A

160 A

6-240 A

59 V

IP23

EN60974-1/EN50199

179x430x290 mm

15.4 Kg

2) PURPOSE OF THE MANUAL

The purpose of this manual is to provide authorised technical ser-

vicing centres the information required for repairing Genesis 240

and Genesis 240 TLH (see NOTE *).

To avoid serious damage to people and things, this manual must

be used strictly by qualified technicians.

What is involved in a repair job?: identifying the faulty part - as

this part is included in the list of available spare parts - and

replacing it according to the procedures described below.

If an electronic card is faulty, repair entails replacing the card

and not replacing the faulty electronic component on the card

itself.

If trouble cannot be solved by observing the procedures in the

manual, the machine must be sent back to SELCO.

We suggest two diagnosis procedures on two levels: at the first

level, simple initial action instruments/tools are used, at the

second level, more sophisticated instruments/tools are used.

By taking into account the training level of its technicians and its

available instruments, each service centre can decide whether

to use the first or second procedure.

The order of the subjects in this manual is based on a logic that

gradually provides the repair technician with knowledge of the

machine. We therefore advise you to follow the suggested

order, by starting at the beginning.

* NOTE : the information contained in this manual does not

apply to the first versions of the machine as specified

in point 10.2.

Purpose of the manual - Machine technical specifications 85

WU15

3) MACHINE TECHNICAL SPECIFICATIONS .

GENESIS 240

GENESIS 240 TLH

Power supply voltage

(50/60Hz)

Max. absorbed power in TIG

(x=40%)

Max. absorbed current in TIG

(x=40%)

Absorbed current in TIG

(x=100%)

Max. absorbed power in MMA

(x=40%)

Max. absorbed current in MMA

(x=40%)

Absorbed current in MMA

(x=100%)

Efficiency (x=40%)

Power factor

Cosj

Welding current (x=40%)

(x=60%)

(x=100%)

Adjustment range

Open-cicuit voltage (limited)

Protection rating

Insulation class

Construction standards

Dimensions (lxpxh)

Weight

3x400V

+10% -10%

6.1 KW

9.3 A

5.4 A

8.5 KW

12.9 A

7.9 A

0.84

0.94

0.99

240 A

185 A

160 A

6-240 A

81 V

IP23

EN60974-1/EN50199

179x430x293 mm

17.4 Kg

Power supply voltage

(50/60Hz)

Nominal input current

Capacity of reservoir

Cooling power

Protection rating

Dimensions (lxpxh)

Weight with liquid

1x230V

+ 10% -10%

0.8 A

1.7 l

900 W

IP23

179x430x160 mm

9.5 Kg

Above data are referred to environment al 40°C.

86 Description of machine parts

4) DESCRIPTION OF MACHINE PARTS.

G 240 consists of the following circuit parts:

(see fig. 1)

a) Master switch

b) input filter for suppressing radio noise and protecting against

mains over-voltage.

c) rectifier bridge

d) power inverter with overtemperature detection device

e) resonant circuit (inductive-capacitive circuit)

f) power transformer

g) rectifier circuit with overtemperature detection device

e) snubber circuit

h) output filter

i) levelling inductance with overtemperature detection device

j) current transducer (Hall effect probe)

k) fan

l) auxiliary transformer

m) power circuits feeding control/adjustment circuits

n) current control circuits

o) control circuits (front panel)

Some of these parts are independent, while others are housed

inside the following electronic cards:

G 240 :

A) Card 15.14.254

B) Card 15.14.239

C) Card 15.14.233

D) Card 15.14.240

E) Card 15.14.238

o) l)

d) e) f) g) h)

FIG. 1

Description of machine parts 87

In the TLH version, the following elements are also present in

addition to the above circuits:

(see fig. 2)

p) H.F. transformer

q) H.F. discharge generation

r) gas solenoid valve

s) cooling unit power supply circuits

Some of these parts are independent, while others are housed

inside the following electronic cards:

G 240 TLH :

F) Card 15.14.254

G) Card 15.14.236

H) Card 15.14.233

I) Card 15.14.240

J) Card 15.14.238

K) Card 15.14.192

i) p)

d)s) e) f) g) h)e)

FIG. 2

88 Description of machine operation

5) DESCRIPTION OF MACHINE OPERATION.

The power undergoes initial AC/DC conversion by the input

rectifier bridge (c) , subsequent AC/DC conversion at high fre-

quency by the inverter (d) , transfer via the insulation transfor-

mer (f) to the output circuits and final AC/DC conversion by the

output rectifier (g) .

More details:

5.1)

Master switch (a) - input filter for suppressing radio noise

and protecting against power line over-voltage (b) .

(see fig. 3-4)

The three power supply cables are cut off by means of the

switch a). The yellow-green cable is fixed to the terminal mar-

ked by the earth symbol and located on the intermediate metal

support.

IMPORTANT !: When accessing parts inside the

machine, remember that turning off the switch will

not prevent the danger of electric shocks. We the-

refore advise you to remove the power plug.

When the switch is closed, the input voltage is applied to the

board 15.14.233 containing the line overvoltage suppressor cir-

cuit (b), consisting of three varistor (see note), and the radio

interference suppressor circuit (b) (see note) connected to earth

via a screw and metal column.

i) p)

d)s) e) f) g) h)e)

NOTE : If the electrical component know as a varistor is placed

between the two power supply phases, when an instantaneous

voltage in excess of 460 V appears on its terminals, the varistor

very rapidly becomes conductive, absorbing a current peak

which is sufficient to limit the said over-voltage and it thus pro-

tects the other parts of the machine.

This process has no destructive effect on the component if the

energy generated by the voltage peak is low, as in the case of

atmospheric lightning strikes. If, however, over-voltage is high

and prolonged, the varistor cannot dissipate this high energy

and blows.

This happens if, for example, the machine is wrongly connected

to 460 Vac mains voltage, or following over-voltage caused by

non stabilised power units of inadequate capacity.

FIG. 3

Description of machine operation 89

NOTE : The radio noise suppression circuit has two purposes:

to keep the machine's radio frequency emissions within limits

specified by standards and to ensure G 240's immunity against

the same type of problems caused by any electronic devices

connected to the same power supply source.

The filter consists of a network of capacitors, some of which are

grounded, and a toroidal inductor.

o) l)

d) e) f) g) h)

FIG. 4

90 Description of machine operation

5.2)

rectifier bridge (c) - power inverter with overtemperature

detection device (d) - resonant circuit (inductive-capacitive

circuit) (e) - power transformer (f)

(see fig. 5-6)

The three-phase power supply voltage is applied to the rectifier

bridge (c), the output of which is connected to the power inverter

(d) via cables no.22(+) and no.23(-).

The inverter has a bridge type structure with four power IGBTs

(one on each branch) welded directly to board 15.14.254 and

fixed to the aluminium radiator by means of screws.

The resonant circuit (inductive-capacitive circuit) at the inverter

output terminals and the presence of an auxiliary circuit on

board 15.14.254 permit operation at high (variable) frequency.

The auxiliary circuit consists of two IGBTs and two power

diodes fixed on the aluminium radiator by means of a profiled

plastic bar, but electrically insulated from the radiator by a strip

of insulating tape with low thermal resistance.

The IGBT switch-on control circuit is located on board

15.14.254.

The radiator is cooled by the air flow generated by the fan (k)

powered at 230Vac. This voltage is insulated from the mains by

means of the auxiliary transformer (l) and protected by a fuse on

board 15.14.233. The air flows from the rear grille (air inlet) of the

machine towards the front grille (air outlet). The inverter is

protected against overloads or blocking of the ventilation air flow

by a radiator temperature detection device; this device sends a

signal to the control logic which then locks the inverter and signals

the fault to the front panel.

The power transformer (f), positioned in series with the inducti-

ve-capacitive load, transfers the power to the output circuits

which are therefore electrically insulated from the power supply

network.

o) l)

d) e) f) g) h)

FIG. 5

Description of machine operation 91

i) p)

d)s) e) f) g) h)e)

FIG. 6

92 Description of machine operation

5.3)

rectifier circuit with overtemperature detection device and

snubber circuit (g) - output filter (h) - levelling inductance with

overtemperature detection device (i).

(see fig. 7-8)

The power transformer output is connected to the two current

rectifier diodes fixed on the aluminium radiator by means of

screws.

Like the inverter, the radiator is cooled by the air flow genera-

ted by the fan. The rectifier circuit is protected against overloads

or blocking of the ventilation air flow by a radiator temperatu-

re detection device; this device sends a signal to the control

logic which then locks the inverter and signals the fault to the

front panel.

The diodes are connected to board 15.14.240 by means of cop-

per bus-bars containing the snubber circuit (g) , the function of

which is to suppress the overvoltages produced at the ends of

the diodes during normal operation.

The output board 15.14.238 contains the output filter (h) .

The levelling inductance (i) at the output guarantees a constant

welding current. The inductance is also thermally protected by

means of a winding temperature detection device which opera-

tes as described above.

o) l)

d) e) f) g) h)

FIG. 7

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